Course Details
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Course Description
Process equipment, structures and piping systems may be subjected to severe service conditions including high constant or fluctuating stresses, extreme temperatures and various types of corrosion. This could cause loss of structural integrity, leading to degradation and damage. If such damage is not detected and assessed in a timely manner, it could result in catastrophic failures with potentially enormous consequential losses of life and assets.
To ensure that engineering systems are capable of handling the service conditions in all foreseeable operating scenarios, they must first be designed through the selection of appropriate materials of construction and in accordance with recognized design methodologies and codes.
It is also important to incorporate safeguards and controls to prevent operation outside the "design and operational envelope" and to inspect the process equipment with the view to detect any damage, characterize it, and assess its impact on the equipment "Fitness For Service".
The Training Course Will Highlight ?
This comprehensive and structured Process Equipment Failures training course aims at providing a clear understanding of the major degradation mechanisms that process equipment and systems will be subjected to during their operating life, how to identify them, their effect on the integrity of the equipment and what appropriate measures can be taken to prevent and control the resultant damage.
Training Objective
This comprehensive and structured Process Equipment Failures training course aims at providing a clear understanding of the major degradation mechanisms that process equipment and systems will be subjected to during their operating life, how to identify them, their effect on the integrity of the equipment and what appropriate measures can be taken to prevent and control the resultant damage.
Target Audience
This BTS training course is intended for:
- Staff who use or supervise activities requiring the selection, design/fabrication or use of mechanical equipment or component parts
- Engineers who seek a basic understanding of the practical aspects of evaluation of structural integrity
- Operation, technical service and maintenance professionals from various processing plants involved in everyday operation, control, inspection and maintenance of equipment.
- Engineers and consultants dealing with planning of new production plants, retrofitting plants and introducing new technologies
- Technical professionals responsible for maintenance and repair of equipment
- Project and asset managers
Training Methods
Daily Agenda
Day One: Materials Testing and Failure
Competency Description: Participants need to gain a sound understanding of methods of mechanical testing of components and methods of failure examination in order to assess the structural integrity of components and equipment.
Key behaviours
- Comprehensive understanding of relevant methods of mechanical testing
- Gain insight into relevant types of failure mechanisms
- Understanding the factors and caused that influence structural failure
- Gain knowledge of the examination of failed components
Topics to be covered
- Course objectives and overview
- Materials Testing – Tensile, Impact, Hardness
- Types of Failures – Ductile/brittle fracture, Temperature Effects
- Analytical Tools – Visual examination of fracture surface, Fractography, Microscopy
- Industrial Failures – Examples of Failures and Causes
Day Two: Damage and Interpretation of Failure I
Competency Description: Participants need to understand relevant failure mechanisms of components, including fracture, fatigue and thermal (high temperature) influence, methods of failure examination and methods of determining the life of components and equipment subjected to several loading conditions.
Key behaviours
- Gain insight into relevant types of failure mechanisms including fracture, fatigue and high temperature applications
- Understanding the internal and external factors and caused that influence structural failure
- Gain knowledge of determining the life of components and equipment subjected to various loading conditions
- Reinforcement of knowledge of component life determination through worked examples
Topics to be covered
- Stress Concentrating
- Fracture Mechanics
- Fatigue Failure
- High temperature Creep
- Thermal Expansion and deflections
- Worked examples
Day Three: Damage and Interpretation of Failure II
Competency Description: Participants need to understand relevant failure mechanisms of components including corrosion and vibration damage, methods of failure examination and methods of determining the life of components and equipment subjected to several loading conditions.
Key behaviours
- Gain insight into relevant types of failure mechanisms including corrosion and vibration damage
- Understanding the internal and external factors and caused that influence structural failure
- Gain knowledge of determining the life of components and equipment subjected to various loading conditions
- Reinforcement of knowledge of component life determination through worked examples
Topics to be covered
- Wear, Galing and Fretting
- Principles and types of Corrosion damage and Mitigation
- Vibration of Equipment and Piping
- Vibration Condition Monitoring
- Technical Problem Solving and Decision-making Approaches
Day Four: Examples of Equipment Failure
Competency Description: Participants need to recognise the failure of specific components and equipment and have a sound understanding of methods of failure mitigation, maintenance and troubleshooting.
Key behaviours
- Appreciate relevant types of failure mechanisms of relevant components and equipment
- Gain knowledge of the examination of failed components and equipment
- Cain an understanding relevant maintenance and troubleshooting issues
Topics to be covered
- Pressure vessels and life extension
- Heat Exchangers
- Pumps and Compressors
- Mechanical Seals and “O” Rign Failures
- Bearing failure
- Pipes and Repair Techniques
Day Five: Inspection, Testing and Condition Assessment
Competency Description: Participants need to gain a sound understanding of methods of equipment inspection and relevant codes
Key behaviours
- Comprehensive understanding of relevant non-destructive testing methods
- Gain insight into estimating the remaining life of equipment and inspection intervals
- Gain knowledge of relevant inspection codes
Topics to be covered
- NDT Methods and Techniques
- Inspection of Process Equipment
- Examples of Remaining Life Calculations
- Relevant Inspection Codes, API 570, etc.
- Course Summary and Wrap-up
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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